How to Replace the Motor Brush Cap on a Porter Cable Router (690 Series)

Running out of patience with a run-down router? It's time to face the fix. Whether you are a master carpenter or a weekend woodworker, eReplacementParts.com provides the parts, procedures and facts you need to fearlessly fix what fails you.

The brush caps install over the motor's brushes. Their purpose is to hold the brushes securely against the armature. Because they are made of plastic, brush caps (especially the threads and heads) are susceptible to damage such as cracking, breaking and stripping. Replacing the caps is very easy to, especially when you follow the steps below. This article provides step-by-step instructions for removing and installing brush caps on a Porter Cable 690 series router.

Let's get started.

  REMOVING THE BRUSH CAP(s) [top] 1. Remove the brush cap(s).

Use a large screwdriver to loosen the brush cap.

Remove the brush cap.

Remove (or inspect) the motor brush. While it is not necessary to actually remove the motor brush from the holder; be aware that the brush is under spring tension and may “eject” itself when the brush cap is removed. Instructions for (re)installing the motor brush are included later in this article.

Repeat this step to remove the second brush cap.

  INSTALLING THE NEW BRUSH CAP(s) [top] 2. Install the brush cap.

Slide the motor brush into the brush holder.

Align the tabs on the motor brush with the slots on the brush holder and compress the brush (spring) into the holder.

Continue holding the compressed motor brush in place with one finger.

Carefully slide the brush cap into position over the compressed motor brush (as you remove your finger from the end of the brush). You may have to attempt this step a few times to get it right. The goal is to install the brush cap without allowing the tabs of the compressed motor brush to spring out of the slots in the brush holder.

Use a large screwdriver to secure the brush cap (do not over-tighten).

Repeat this step to install the remaining brush cap.

Dovetails. Rabbets. Dados. Grooves: The possibilities are as priceless as machines that create them. But you don't have to be a carpenter to cut out the middle-man. Repairing your own powered equipment is easy and economical when you follow our step-by-step guides. Not only did you restore your router at a fraction of the cost of replacement; you built on your ability to face the next fix, whatever it may be.

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